Mechanical Engineer

Badri Belur

**** ***** **, *** #**, Champaign, IL-61822 • Phone: 937-***-**** • E-mail: *****@*****.***

Profile: Eight years of hands-on experience in Product/Process Design, Finite element analysis, and Project Management; specializing in process design and improvement.

Skills:

* Design and analysis

* Project Management

* Develop methods to increase and improve productivity

* Six Sigma Green belt certified

* Design verification and validation

* Design of Experiments

Technical Competence:

FEA Packages: Abaqus, Hyperform, DEFORM, MAGMA, DANTE, AdvantEdge, ANSYS

Meshing tools: Hypermesh, ANSA, CUBIT, NX6

Modeling Packages: I-DEAS, Pro-E, AutoCAD 2000

Programming Languages: Perl, Python, MATLAB, C, Mathematica

Experience:

Caterpillar, Champaign Simulation Center Champaign, IL

Sr. Project Engineer November 2004 – February 2009

Worked with various Caterpillar business units, foundries and forge shops to design and improve manufacturing processes.

* Conducted and coordinated Design, Modeling, Analysis (Fluid flow, Casting, Metal Forming, Thermal Stress, Non-Linear Structural, Life-Cycle Analysis, etc.) and Optimization

* Successfully integrated multi-stage design analysis to determine the effect of process history on final part dimensions and residual stresses in the final part

* Initiated, Developed and Implemented strategies to improve resource utilization and productivity

* Evaluated various 2D and 3D software’s for benchmarking and validation purposes

* Utilized Six Sigma to determine the best Pre/ Post processing tool for the company

* Collaborated with other teams on various projects to provide quick turnaround on critical project and Presenting updates to customers

Major Accomplishment: Reduced Cost and Number of actual casting iterations by optimizing part design to improve manufacturability and providing validation through simulation

Wright State University, Dept of Mechanical Engineering Dayton, OH

Graduate Research/Teaching Assistant April 2001 –April 2004

Worked on a project funded by National Institute of Standards and Technology (NIST) and Advanced Technology Program (ATP) to design and develop a real time quality control system for the manufacturing industry (forging).

* Investigated and developed a strategy for project implementation and execution

* Developed of uncertainty-based database generation using 3D design (I-DEAS, ABAQUS/Dante) of the cooling process of a forged part

* Implemented Six-sigma processes to improve reliability of the forging process design

* Coordinated, scheduled and assigned of duties to execute projects

Taught the process of measuring mechanical vibration and various machining procedures to students by conducting experiments in the vibration lab and machining lab

* Determined modal frequency of a cruse missile fin using SIG LAB

* Introduced concepts of machining and geometric drawing and tolerance

Major Accomplishments: Developed methodology to predict final part dimensions from hot part dimensions during forging which providing 100% Quality Control in real time without human intervention

Neela Industries Bangalore, India

Technical Supervisor August 1993 - October 2000

Worked with various types and models of automobiles, performing fault diagnosing, rectification and maintenance in gasoline and diesel engine cars, dismantling and overhauling of engine, gearbox, transmission, suspension, etc, conversion of gasoline engine cars to LPG fueled

Education:

Master of Science, Mechanical Engineering Dayton, OH

Wright State University April 2004

Bachelor of Science, Automotive Engineering Hassan, India

University of Mysore August 1999

Honor: First Class with Academic Distinction, Received Merit incentives in Engineering

Diploma in Automobile Engineering Bangalore, India

Board of Technical Education, Karnataka August 1995

Honor: Ranked sixth in the state

Projects and Publications:

1. Thesis: “Uncertainty Quantification and Dimension Prediction In Forging And Cooling Processes,” March, 2004.

2. Belur.K.Badrinarayan and Ramana.V.Grandhi, “Geometric Deviations in Forging and Cooling Operations Due to Process Uncertainties,” Journal of Materials Processing Technology, Vol. 152, No.2, 2004, pp. 204-214

3. Nagarajan Thiyagarajan, Jalaja Repalle, Belur.K.Badrinarayan, and Ramana.V.Grandhi, “Forged Part Distortion Prediction and Minimization,” AIAA/ICAS International Air and Space Symposium and Exposition: The Next 100 Years, Dayton, Ohio, July 14 - 17, 2003.

4. Belur.K.Badrinarayan and Ramana.V.Grandhi, “Thermo-Mechanically Induced Geometric Variation Estimator in Metal Forming,” Presented at 28th Annual Dayton-Cincinnati Aerospace Sciences Symposium, March 5, 2003.

5. Belur.K.Badrinarayan, Zhichao Li and Ramana.V.Grandhi, “Gas Quenching Process Optimization of Forgings Using Finite Element Method,” Presented at 24th Forging Industry Technical Conference, October 14-16, 2002.

6. Belur.K.Badrinarayan and Ramana.V.Grandhi, “Development of a Thermo-mechanically Induced Geometric Variation Estimator,” Presented at 27th Annual Dayton-Cincinnati Aerospace Sciences Symposium, March 5, 2002.

7. Design Project: “Failure Detection and Audio Warning System in Automobiles using Simple Integrated Circuits”: Developed a simple foolproof electronic circuitry with self-designed printed circuit board, that indicates failures and gives forewarning in the event of a weak / degrading part or mechanism

Leadership:

Aviation club, Wright State University, Secretary and Treasurer, 2001-2003.

Hobbies:

Flying model and Real planes (Private Pilot), Skydiving

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